Activation features for ultrasonic surgical instrument

ABSTRACT

An ultrasonic instrument includes a body, an actuation assembly, a shaft assembly, and an ultrasonic blade. The body defines a longitudinal axis and is configured to receive an ultrasonic transducer. The actuation assembly includes at least one annular activation member and at least one circuit. The at least one annular activation member extends angularly about the body along a 360 degree angular range. The at least one annular activation member is configured to move laterally relative to the longitudinal axis of the body. The at least one circuit corresponds to the at least one annular activation member. The shaft assembly includes an acoustic waveguide. The ultrasonic blade is in acoustic communication with the acoustic waveguide. The at least one activation circuit is configured to activate the ultrasonic blade in response to lateral movement of the activation member relative to the longitudinal axis of the body.

This application is a continuation of U.S. patent application Ser. No.14/833,288, entitled “Activation Features for Ultrasonic SurgicalInstrument,” filed Aug. 24, 2015, issued as U.S. Pat. No. 10,321,930 onJun. 18, 2019.

BACKGROUND

A variety of surgical instruments include an end effector having a bladeelement that vibrates at ultrasonic frequencies to cut and/or sealtissue (e.g., by denaturing proteins in tissue cells). These instrumentsinclude one or more piezoelectric elements that convert electrical powerinto ultrasonic vibrations, which are communicated along an acousticwaveguide to the blade element. The precision of cutting and coagulationmay be controlled by the operator's technique and adjusting the powerlevel, blade edge angle, tissue traction, and blade pressure.

Examples of ultrasonic surgical instruments include the HARMONIC ACE®Ultrasonic Shears, the HARMONIC WAVE® Ultrasonic Shears, the HARMONICFOCUS® Ultrasonic Shears, and the HARMONIC SYNERGY® Ultrasonic Blades,all by Ethicon Endo-Surgery, Inc. of Cincinnati, Ohio. Further examplesof such devices and related concepts are disclosed in U.S. Pat. No.5,322,055, entitled “Clamp Coagulator/Cutting System for UltrasonicSurgical Instruments,” issued Jun. 21, 1994, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 5,873,873, entitled“Ultrasonic Clamp Coagulator Apparatus Having Improved Clamp Mechanism,”issued Feb. 23, 1999, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 5,980,510, entitled “Ultrasonic ClampCoagulator Apparatus Having Improved Clamp Arm Pivot Mount,” issued Nov.9, 1999, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 6,283,981, entitled “Method of Balancing AsymmetricUltrasonic Surgical Blades,” issued Sep. 4, 2001, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 6,309,400,entitled “Curved Ultrasonic Blade having a Trapezoidal Cross Section,”issued Oct. 30, 2001, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 6,325,811, entitled “Blades withFunctional Balance Asymmetries for use with Ultrasonic SurgicalInstruments,” issued Dec. 4, 2001, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 6,423,082, entitled“Ultrasonic Surgical Blade with Improved Cutting and CoagulationFeatures,” issued Jul. 23, 2002, the disclosure of which is incorporatedby reference herein; U.S. Pat. No. 6,773,444, entitled “Blades withFunctional Balance Asymmetries for Use with Ultrasonic SurgicalInstruments,” issued Aug. 10, 2004, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 6,783,524, entitled“Robotic Surgical Tool with Ultrasound Cauterizing and CuttingInstrument,” issued Aug. 31, 2004, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 8,057,498, entitled“Ultrasonic Surgical Instrument Blades,” issued Nov. 15, 2011, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.8,461,744, entitled “Rotating Transducer Mount for Ultrasonic SurgicalInstruments,” issued Jun. 11, 2013, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 8,591,536, entitled“Ultrasonic Surgical Instrument Blades,” issued Nov. 26, 2013, thedisclosure of which is incorporated by reference herein; and U.S. Pat.No. 8,623,027, entitled “Ergonomic Surgical Instruments,” issued Jan. 7,2014, the disclosure of which is incorporated by reference herein.

Still further examples of ultrasonic surgical instruments are disclosedin U.S. Pub. No. 2006/0079874, entitled “Tissue Pad for Use with anUltrasonic Surgical Instrument,” published Apr. 13, 2006, now abandoned,the disclosure of which is incorporated by reference herein; U.S. Pub.No. 2007/0191713, entitled “Ultrasonic Device for Cutting andCoagulating,” published Aug. 16, 2007, now abandoned, the disclosure ofwhich is incorporated by reference herein; U.S. Pub. No. 2007/0282333,entitled “Ultrasonic Waveguide and Blade,” published Dec. 6, 2007, nowabandoned, the disclosure of which is incorporated by reference herein;U.S. Pub. No. 2008/0200940, entitled “Ultrasonic Device for Cutting andCoagulating,” published Aug. 21, 2008 now abandoned, the disclosure ofwhich is incorporated by reference herein; U.S. Pub. No. 2008/0234710,entitled “Ultrasonic Surgical Instruments,” published Sep. 25, 2008,issued as U.S. Pat. No. 8,911,460 on Dec. 16, 2014, the disclosure ofwhich is incorporated by reference herein; and U.S. Pub. No.2010/0069940, entitled “Ultrasonic Device for Fingertip Control,”published Mar. 18, 2010, issued as U.S. Pat. No. 9,023,071 on May 5,2015, the disclosure of which is incorporated by reference herein.

Some ultrasonic surgical instruments may include a cordless transducersuch as that disclosed in U.S. Pub. No. 2012/0112687, entitled “RechargeSystem for Medical Devices,” published May 10, 2012, issued as U.S. Pat.No. 9,381,058 on Jul. 5, 2016, the disclosure of which is incorporatedby reference herein; U.S. Pub. No. 2012/0116265, entitled “SurgicalInstrument with Charging Devices,” published May 10, 2012 now abandoned,the disclosure of which is incorporated by reference herein; and/or U.S.Pat. App. No. 61/410,603, filed Nov. 5, 2010, entitled “Energy-BasedSurgical Instruments,” the disclosure of which is incorporated byreference herein.

Additionally, some ultrasonic surgical instruments may include anarticulating shaft section. Examples of such ultrasonic surgicalinstruments are disclosed in U.S. Pub. No. 2014/0005701, published Jan.2, 2014, issued as U.S. Pat. No. 9,393,037 on Jul. 19, 2016, entitled“Surgical Instruments with Articulating Shafts,” the disclosure of whichis incorporated by reference herein; and U.S. Pub. No. 2014/0114334,published Apr. 24, 2014, issued as U.S. Pat. No. 9,095,367 on Aug. 4,2015, entitled “Flexible Harmonic Waveguides/Blades for SurgicalInstruments,” the disclosure of which is incorporated by referenceherein.

While several surgical instruments and systems have been made and used,it is believed that no one prior to the inventors has made or used theinvention described in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims which particularly pointout and distinctly claim this technology, it is believed this technologywill be better understood from the following description of certainexamples taken in conjunction with the accompanying drawings, in whichlike reference numerals identify the same elements and in which:

FIG. 1 depicts a block schematic view of an exemplary surgical system;

FIG. 2 depicts a perspective view of an exemplary surgical instrumentthat may be incorporated into the system of FIG. 1;

FIG. 3 depicts a block schematic view of an exemplary multi-buttonactivation circuit that may be incorporated into the instrument of FIG.2;

FIG. 4 depicts a perspective view of an exemplary alternative handleassembly that may be incorporated into the instrument of FIG. 2;

FIG. 5 depicts a side cross-sectional view of the handle assembly ofFIG. 4, with the cross-section taken along line 5-5 of FIG. 4;

FIG. 6 depicts a front cross-sectional view of the handle assembly ofFIG. 4, with the cross-section taken along line 6-6 of FIG. 4;

FIG. 7 depicts another side cross-sectional view of the handle assemblyof FIG. 4, with a pair of activation rings in an unactivated position;

FIG. 8 depicts still another side cross-sectional view of the handleassembly of FIG. 4, with a first activation ring in an activatedposition;

FIG. 9 depicts yet another side cross-sectional view of the handleassembly of FIG. 4, with a second activation ring in an activatedposition;

FIG. 10 depicts a perspective view of another exemplary alternativehandle assembly that may be incorporated into the instrument of FIG. 2;

FIG. 11 depicts a side cross-sectional view of the handle assembly ofFIG. 10, with the cross-section taken along line 11-11 of FIG. 10;

FIG. 12 depicts a front cross-sectional view of the handle assembly ofFIG. 10, with the cross-section taken along line 12-12 of FIG. 10;

FIG. 13 depicts another side cross-sectional view of the handle assemblyof FIG. 10, with a pair of activation rings in a neutral position;

FIG. 14 depicts still another side cross-sectional view of the handleassembly of FIG. 10, with a first activation ring in an activatedposition;

FIG. 15 depicts yet another side cross-sectional view of the handleassembly of FIG. 10, with a second activation ring in an activatedposition;

FIG. 16 depicts a side cross-sectional view of still another handleassembly that may be incorporated into the instrument of FIG. 2;

FIG. 17 depicts another side cross-sectional view of the handle assemblyof FIG. 16, with a first activation ring in an activated position;

FIG. 18 depicts still another side cross-sectional view of the handleassembly of FIG. 15, with a second activation ring in an activatedposition;

FIG. 19 depicts a front perspective view of the handle assembly of FIG.4, with the handle assembly equipped with a lock insert;

FIG. 20 depicts a side cross-sectional view of the handle assembly ofFIG. 19, with the cross-section taken along line 20-20 of FIG. 19;

FIG. 21 depicts another side cross-sectional view of the handle assemblyof FIG. 19, with a lock insert removed;

FIG. 22 depicts a perspective view of yet another exemplary alternativehandle assembly that may be incorporated into the instrument of FIG. 2;

FIG. 23 depicts a side cross-sectional view of the handle assembly ofFIG. 22, with the cross-section taken along line 23-23 of FIG. 22; and

FIG. 24 depicts another side cross-sectional view of the handle assemblyof FIG. 22, with a lock assembly in an unlocked position.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the technology may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presenttechnology, and together with the description serve to explain theprinciples of the technology; it being understood, however, that thistechnology is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the technology shouldnot be used to limit its scope. Other examples, features, aspects,embodiments, and advantages of the technology will become apparent tothose skilled in the art from the following description, which is by wayof illustration, one of the best modes contemplated for carrying out thetechnology. As will be realized, the technology described herein iscapable of other different and obvious aspects, all without departingfrom the technology. Accordingly, the drawings and descriptions shouldbe regarded as illustrative in nature and not restrictive.

It is further understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Thefollowing-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

For clarity of disclosure, the terms “proximal” and “distal” are definedherein relative to an operator or other operator grasping a surgicalinstrument having a distal surgical end effector. The term “proximal”refers the position of an element closer to the operator or otheroperator and the term “distal” refers to the position of an elementcloser to the surgical end effector of the surgical instrument andfurther away from the operator or other operator.

I. Overview of Exemplary Ultrasonic Surgical System

FIG. 1 shows components of an exemplary surgical system (10) indiagrammatic block form. As shown, system (10) comprises an ultrasonicgenerator (12) and an ultrasonic surgical instrument (20). As will bedescribed in greater detail below, instrument (20) is operable to cuttissue and seal or weld tissue (e.g., a blood vessel, etc.)substantially simultaneously, using ultrasonic vibrational energy. Byway of example only, instrument (20) may be constructed and operable inaccordance with at least some of the teachings of U.S. Pat. Nos.5,322,055; 5,873,873; 5,980,510; 6,325,811; 6,773,444; 6,783,524;9,095,367; U.S. Pub. No. 2006/0079874, now abandoned; U.S. Pub. No.2007/0191713, now abandoned; U.S. Pub. No. 2007/0282333, now abandoned;U.S. Pub. No. 2008/0200940, now abandoned; U.S. Pub. No. 2009/0105750,issued as U.S. Pat. No. 8,623,027 on Jan. 7, 2014; U.S. Pub. No.2010/0069940, issued as U.S. Pat. No. 9,023,071; U.S. Pub. No.2011/0015660, issued as U.S. Pat. No. 8,461,744 on Jun. 11, 2013; U.S.Pub. No. 2012/0112687, issued as U.S. Pat. No. 9,381,058; U.S. Pub. No.2012/0116265, now abandoned; U.S. Pub. No. 2014/0005701, issued as U.S.Pat. No. 9,393,037; U.S. Pub. No. 2015/0080924, issued as U.S. Pat. No.10,172,636 on Jan. 8, 2019; and/or U.S. Pat. App. No. 61/410,603. Thedisclosures of each of the foregoing patents, publications, andapplications are incorporated by reference herein.

It should also be understood that instrument (20) may have variousstructural and functional similarities with the HARMONIC ACE® UltrasonicShears, the HARMONIC WAVE® Ultrasonic Shears, the HARMONIC FOCUS®Ultrasonic Shears, and/or the HARMONIC SYNERGY® Ultrasonic Blades.Furthermore, instrument (20) may have various structural and functionalsimilarities with the devices taught in any of the other references thatare cited and incorporated by reference herein. To the extent that thereis some degree of overlap between the teachings of the references citedherein, the HARMONIC ACE® Ultrasonic Shears, the HARMONIC WAVE®Ultrasonic Shears, the HARMONIC FOCUS® Ultrasonic Shears, and/or theHARMONIC SYNERGY® Ultrasonic Blades, and the following teachingsrelating to instrument (20), there is no intent for any of thedescription herein to be presumed as admitted prior art. Severalteachings herein will in fact go beyond the scope of the teachings ofthe references cited herein and the HARMONIC ACE® Ultrasonic Shears, theHARMONIC WAVE® Ultrasonic Shears, the HARMONIC FOCUS® Ultrasonic Shears,and the HARMONIC SYNERGY® Ultrasonic Blades.

Generator (12) and instrument (20) are coupled together via cable (14).Cable (14) may comprise a plurality of wires; and may provideunidirectional electrical communication from generator (12) toinstrument (20) and/or bidirectional electrical communication betweengenerator (12) and instrument (20). By way of example only, generator(12) may comprise the GEN04, GEN11, or GEN 300 sold by EthiconEndo-Surgery, Inc. of Cincinnati, Ohio. In addition or in thealternative, generator (12) may be constructed in accordance with atleast some of the teachings of U.S. Pub. No. 2011/0087212, entitled“Surgical Generator for Ultrasonic and Electrosurgical Devices,”published Apr. 14, 2011, issued as U.S. Pat. No. 8,986,302 on Mar. 24,2015, the disclosure of which is incorporated by reference herein.Alternatively, any other suitable generator (12) may be used. As will bedescribed in greater detail below, generator (12) is operable to providepower to instrument (20) to perform ultrasonic surgical procedures. Itshould also be understood that some versions of system (10) mayincorporate generator (12) into instrument (20), such that cable (14)may simply be omitted.

Instrument (20) comprises a handle assembly (22), which is configured tobe grasped in one hand (or two hands) of an operator and manipulated byone hand (or two hands) of the operator during a surgical procedure. Forinstance, in some versions, handle assembly (22) may be grasped like apencil by the operator. In some other versions, handle assembly (22) mayinclude a scissor grip that may be grasped like scissors by theoperator. In some other versions, handle assembly (22) may include apistol grip that may be grasped like a pistol by the operator. Ofcourse, handle assembly (22) may be configured to be gripped in anyother suitable fashion. Furthermore, some versions of instrument (20)may substitute handle assembly (22) with a body that is coupled to arobotic surgical system that is configured to operate instrument (e.g.,via remote control, etc.).

In the present example, a blade (24) extends distally from the handleassembly (22). Handle assembly (22) includes an ultrasonic transducer(26) and an ultrasonic waveguide (28), which couples ultrasonictransducer (26) with blade (24). Ultrasonic transducer (26) receiveselectrical power from generator (12) via cable (14). By virtue of itspiezoelectric properties, ultrasonic transducer (26) is operable toconvert such electrical power into ultrasonic vibrational energy.

Ultrasonic waveguide (28) may be flexible, semi-flexible, rigid, or haveany other suitable properties. As noted above, ultrasonic transducer(26) is integrally coupled with blade (24) via ultrasonic waveguide(28). In particular, when ultrasonic transducer (26) is activated tovibrate at ultrasonic frequencies, such vibrations are communicatedthrough ultrasonic waveguide (28) to blade (24), such that blade (24)will also vibrate at ultrasonic frequencies. When blade (24) is in anactivated state (i.e., vibrating ultrasonically), blade (24) is operableto effectively cut through tissue and seal tissue. Ultrasonic transducer(26), ultrasonic waveguide (28), and blade (24) together thus form anacoustic assembly providing ultrasonic energy for surgical procedureswhen powered by generator (12). Handle assembly (22) is configured tosubstantially isolate the operator from the vibrations of the acousticassembly formed by transducer (26), ultrasonic waveguide (28), and blade(24).

In some versions, ultrasonic waveguide (28) may amplify the mechanicalvibrations transmitted through ultrasonic waveguide (28) to blade (24).Ultrasonic waveguide (28) may further have features to control the gainof the longitudinal vibration along ultrasonic waveguide (28) and/orfeatures to tune ultrasonic waveguide (28) to the resonant frequency ofsystem (10). For instance, ultrasonic waveguide (28) may have anysuitable cross-sectional dimensions/configurations, such as asubstantially uniform cross-section, be tapered at various sections, betapered along its entire length, or have any other suitableconfiguration. Ultrasonic waveguide (28) may, for example, have a lengthsubstantially equal to an integral number of one-half system wavelengths(nλ/2). Ultrasonic waveguide (28) and blade (24) may be fabricated froma solid core shaft constructed out of a material or combination ofmaterials that propagates ultrasonic energy efficiently, such astitanium alloy (i.e., Ti-6Al-4V), aluminum alloys, sapphire, stainlesssteel, or any other acoustically compatible material or combination ofmaterials.

In the present example, the distal end of blade (24) is located at aposition corresponding to an anti-node associated with resonantultrasonic vibrations communicated through waveguide (28) (i.e., at anacoustic anti-node), in order to tune the acoustic assembly to apreferred resonant frequency f_(o) when the acoustic assembly is notloaded by tissue. When transducer (26) is energized, the distal end ofblade (24) is configured to move longitudinally in the range of, forexample, approximately 10 to 500 microns peak-to-peak, and in someinstances in the range of about 20 to about 200 microns at apredetermined vibratory frequency f_(o) of, for example, 55.5 kHz. Whentransducer (26) of the present example is activated, these mechanicaloscillations are transmitted through waveguide (28) to reach blade (24),thereby providing oscillation of blade (24) at the resonant ultrasonicfrequency. Thus, the ultrasonic oscillation of blade (24) maysimultaneously sever the tissue and denature the proteins in adjacenttissue cells, thereby providing a coagulative effect with relativelylittle thermal spread. In some versions, an electrical current may alsobe provided through blade (24) to also cauterize the tissue.

By way of example only, ultrasonic waveguide (28) and blade (24) maycomprise components sold under product codes SNGHK and SNGCB by EthiconEndo-Surgery, Inc. of Cincinnati, Ohio. By way of further example only,ultrasonic waveguide (28) and/or blade (24) may be constructed andoperable in accordance with the teachings of U.S. Pat. No. 6,423,082,entitled “Ultrasonic Surgical Blade with Improved Cutting andCoagulation Features,” issued Jul. 23, 2002, the disclosure of which isincorporated by reference herein. As another merely illustrativeexample, ultrasonic waveguide (28) and/or blade (24) may be constructedand operable in accordance with the teachings of U.S. Pat. No.5,324,299, entitled “Ultrasonic Scalpel Blade and Methods ofApplication,” issued Jun. 28, 1994, the disclosure of which isincorporated by reference herein. Other suitable properties andconfigurations of ultrasonic waveguide (28) and blade (24) will beapparent to those of ordinary skill in the art in view of the teachingsherein.

Handle assembly (22) of the present example also includes a controlselector (30) and an activation switch (32), which are each incommunication with a circuit board (34). By way of example only, circuitboard (34) may comprise a conventional printed circuit board, a flexcircuit, a rigid-flex circuit, or may have any other suitableconfiguration. Control selector (30) and activation switch (32) may bein communication with circuit board (34) via one or more wires, tracesformed in a circuit board or flex circuit, and/or in any other suitablefashion. Circuit board (34) is coupled with cable (14), which is in turncoupled with control circuitry (16) within generator (12). Activationswitch (32) is operable to selectively activate power to ultrasonictransducer (26). In particular, when switch (32) is activated, suchactivation provides communication of appropriate power to ultrasonictransducer (26) via cable (14). By way of example only, activationswitch (32) may be constructed in accordance with any of the teachingsof the various references cited herein. Other various forms thatactivation switch (32) may take will be apparent to those of ordinaryskill in the art in view of the teachings herein.

In the present example, surgical system (10) is operable to provide atleast two different levels or types of ultrasonic energy (e.g.,different frequencies and/or amplitudes, etc.) at blade (24). To thatend, control selector (30) is operable to permit the operator to selecta desired level/amplitude of ultrasonic energy. By way of example only,control selector (30) may be constructed in accordance with any of theteachings of the various references cited herein. Other various formsthat control selector (30) may take will be apparent to those ofordinary skill in the art in view of the teachings herein. In someversions, when an operator makes a selection through control selector(30), the operator's selection is communicated back to control circuitry(16) of generator (12) via cable (14), and control circuitry (16)adjusts the power communicated from generator (12) accordingly the nexttime the operator actuates activation switch (32).

It should be understood that the level/amplitude of ultrasonic energyprovided at blade (24) may be a function of characteristics of theelectrical power communicated from generator (12) to instrument (20) viacable (14). Thus, control circuitry (16) of generator (12) may provideelectrical power (via cable (14)) having characteristics associated withthe ultrasonic energy level/amplitude or type selected through controlselector (30). Generator (12) may thus be operable to communicatedifferent types or degrees of electrical power to ultrasonic transducer(26), in accordance with selections made by the operator via controlselector (30). In particular, and by way of example only, generator (12)may increase the voltage and/or current of the applied signal toincrease the longitudinal amplitude of the acoustic assembly. As amerely illustrative example, generator (12) may provide selectabilitybetween a “level 1” and a “level 5,” which may correspond with avibrational resonance amplitude of approximately 50 microns andapproximately 90 microns, respectively. Various ways in which controlcircuitry (16) may be configured will be apparent to those of ordinaryskill in the art in view of the teachings herein. It should also beunderstood that control selector (30) and activation switch (32) may besubstituted with two or more activation switches (32). In some suchversions, one activation switch (32) is operable to activate blade (24)at one power level/type while another activation switch (32) is operableto activate blade (24) at another power level/type, etc.

In some alternative versions, control circuitry (16) is located withinhandle assembly (22). For instance, in some such versions, generator(12) only communicates one type of electrical power (e.g., just onevoltage and/or current available) to handle assembly (22), and controlcircuitry (16) within handle assembly (22) is operable to modify theelectrical power (e.g., the voltage of the electrical power), inaccordance with selections made by the operator via control selector(30), before the electrical power reaches ultrasonic transducer (26).Furthermore, generator (12) may be incorporated into handle assembly(22) along with all other components of surgical system (10). Forinstance, one or more batteries (not shown) or other portable sources ofpower may be provided in handle assembly (22). Still other suitable waysin which the components depicted in FIG. 1 may be rearranged orotherwise configured or modified will be apparent to those of ordinaryskill in the art in view of the teachings herein.

II. Overview of Exemplary Ultrasonic Surgical Instrument

The following discussion relates to various exemplary components andconfigurations for instrument (20). It should be understood that thevarious examples of instrument (20) described below may be readilyincorporated into a surgical system (10) as described above. It shouldalso be understood that the various components and operability ofinstrument (20) described above may be readily incorporated into theexemplary versions of instrument (20) described below. Various suitableways in which the above and below teachings may be combined will beapparent to those of ordinary skill in the art in view of the teachingsherein. It should also be understood that the below teachings may bereadily combined with the various teachings of the references that arecited herein.

FIG. 2 illustrates an exemplary ultrasonic surgical instrument (120)that may be used as instrument (20) of system (10) described above. Atleast part of instrument (120) may therefore be constructed and operablein accordance with at least some of the teachings above with respect toinstrument (20). As with instrument (20), instrument (120) is operableto cut tissue and seal or weld tissue (e.g., a blood vessel, etc.)substantially simultaneously. Instrument (210) of this example isconfigured to be used as a scalpel. As will be described in greaterdetail below, instrument (120) provides enhanced access to activationfeatures.

As shown in FIG. 2, instrument (120) of this example comprises a handleassembly (130), a shaft assembly (140), and an end effector (150). Theproximal end of instrument (120) receives and is fitted with anultrasonic transducer (126) by insertion of ultrasonic transducer (126)into handle assembly (130). Handle assembly (130) is configured toreceive ultrasonic transducer (126) such that ultrasonic transducer(126) may be coupled to a waveguide (148) in shaft assembly (140) by athreaded connection, though any other suitable type of coupling may beused. As shown, instrument (120) may be coupled with ultrasonictransducer (226) to form a single unit.

Shaft assembly (140) comprises an outer sheath (142) and a waveguide(148) disposed within outer sheath (142). In some versions, outer sheath(142) and waveguide (148) are sized to fit through a trocar or otherminimally invasive access port, such that instrument (120) may be usedin a minimally invasive surgical procedure. Waveguide (148) isconfigured to transmit ultrasonic vibrations from transducer (126) to anultrasonic blade (152). Waveguide (148) may be flexible, semi-flexibleor rigid. Waveguide (148) may also be configured to amplify themechanical vibrations transmitted through waveguide (148) to blade(152). Waveguide (148) may further include at least one bore (not shown)extending therethrough, substantially perpendicular to the longitudinalaxis of waveguide (248). The bore may be located at a longitudinalposition corresponding to a node associated with ultrasonic vibrationscommunicated along waveguide (148). The bore may be configured toreceive a connector pin (not shown) that connects waveguide (148) toouter sheath (142). Since the connector pin would be located at a nodalposition, the pin would not transmit ultrasonic vibrations fromwaveguide (148) to outer sheath (142); yet the connector pin may stillprovide a longitudinal and rotational ground for outer sheath (142).

Blade (152) may be integral with the ultrasonic waveguide and formed asa single unit. In some versions, blade (152) may be connected towaveguide (148) by a threaded connection, a welded joint, and/or someother coupling feature(s). The distal end of blade (152) is disposed ator near a longitudinal position corresponding to an anti-node associatedwith ultrasonic vibrations communicated along waveguide (148) and blade(152) in order to tune the acoustic assembly to a preferred resonantfrequency f_(o) when the acoustic assembly is not loaded by tissue. Whentransducer (126) is energized, the distal end of blade (152) isconfigured to move substantially longitudinally (along the x axis) inthe range of, for example, approximately 10 to 500 microns peak-to-peak,and perhaps in the range of about 20 to about 200 microns, at apredetermined vibrational frequency f_(o) of, for example, 55,500 Hz.The distal end of blade (152) may also vibrate in the y-axis at about 1to about 10 percent of the motion in the x-axis. Of course, movement ofblade (152) when transducer (126) is energized may alternatively haveany other suitable characteristics.

Handle assembly (130) comprises a tubular elongate body (132) includinga plurality of buttons (136). Elongate body (132) is configured topermit a user to grip handle assembly (130) from a variety of positions.By way of example only, handle assembly (130) may be shaped to begrasped and manipulated in a pencil-grip arrangement, in ascrewdriver-grip arrangement, and/or in any other suitable fashion.Handle assembly (130) of the present example comprises mating housingportions (137) and (138), though it should be understood that handleassembly (130) may alternatively comprise just a single housingcomponent. Housing portions (137, 138) may be constructed from a durableplastic, such as polycarbonate or a liquid crystal polymer. It is alsocontemplated that housing portions (137, 138) may alternatively be madefrom a variety of materials or combinations of materials, including butnot limited to other plastics, ceramics, and/or metals, etc.

In the present example, body (132) of handle assembly (130) includes aproximal end, a distal end, and a cavity (not shown) extendinglongitudinally therein. The cavity is configured to accept a switchassembly (now shown), an actuation assembly (not shown), and at least aportion of ultrasonic transducer assembly (126), all in a manner similarto the teachings of U.S. patent application Ser. No. 14/515,129,entitled “Activation Features for Ultrasonic Surgical Instrument,” filedOct. 15, 2014, issued as U.S. Pat. No. 9,907,565 on Mar. 6, 2018, thedisclosure of which is incorporated by reference herein. In the presentexample, the distal end of transducer (126) threadably attaches to theproximal end of the waveguide, though any other suitable type ofcoupling may be used.

Electrical contacts of transducer (126) also interface with the switchassembly to provide the operator with finger-activated controls onsurgical instrument (120). Transducer (126) of the present exampleincludes two conductive rings (not shown) that are securely disposedwithin the body of transducer (126). By way of example only, suchconductive rings and/or other features of transducer (126) may beprovided in accordance with at least some of the teachings of U.S. Pat.No. 8,152,825, entitled “Medical Ultrasound System and Handpiece andMethods for Making and Tuning,” issued Apr. 10, 2012, the disclosure ofwhich is incorporated by reference herein.

The switch assembly provides an electro-mechanical interface betweenbuttons (136) of handle assembly (130) and generator (12) via transducer(126) such that actuation of any of buttons (136) results in theactivation of generator (12), which in turn activates transducer (126)to generate ultrasonic vibrations along waveguide (148) and blade (152).By way of example only, various components of switch assembly mayinterface with transducer (126) via ring conductors of transducer (126),which are in turn connected to conductors in cable (14) that connects togenerator (12). Thus, when contact switch of switch assembly is actuatedby the depressing of any of buttons (136), generator (12) activatestransducer (126) to generate ultrasonic vibrations. Buttons (236) areprovided in an annular array in this example, with buttons (236) beingangularly spaced from each other equidistantly. Buttons (136) may beconstructed and operable in accordance with at least some of theteachings of U.S. patent application Ser. No. 14/515,129, entitled“Activation Features for Ultrasonic Surgical Instrument,” filed Oct. 15,2014, issued as U.S. Pat. No. 9,907,565 on Mar. 6, 2018, the disclosureof which is incorporated by reference herein.

It should be understood that providing buttons (136) in an angular arraymay enable the operator to actuate one or more buttons (136) (andthereby activate transducer (126) and blade (152)) at various grippingpositions about the longitudinal axis of handle assembly (130). In otherwords, the operator will not need to contort their fingers, hand, wrist,or arm in order to activate transducer (126) and blade (152) fromwhichever angular orientation the operator happens to be grasping handleassembly (130). This enhanced access to buttons (136) may beparticularly useful when blade (152) has an asymmetry, such thatengaging tissue with different sides of blade (152) (e.g., with blade(152) oriented at different angular orientations about the longitudinalaxis of waveguide (148)) will provide different effects on tissue. Theoperator will thus not be forced to sacrifice ergonomic comfort in orderto selectively achieve various orientations of blade (152) relative totissue.

III. Exemplary Alternative Handle Assemblies with Circular Buttons

As noted above, there may be instances where it is desirable to enablean operator to engage tissue with an ultrasonic blade at variousdifferent angular orientations about the longitudinal axis of anultrasonic waveguide that is coupled with the ultrasonic blade. This maybe particularly desirable where the ultrasonic blade has an asymmetry,such the effect that the activated blade has on tissue will varydepending on the angular orientation (about the longitudinal axis of thewaveguide) at which the blade engages tissue. It may therefore bedesirable to enable the operator to continue to grasp and manipulate thehandle assembly in the same way regardless of the angular orientation(about the longitudinal axis of the waveguide and the handle assembly)at which the handle assembly is positioned in the operator's hand. Whilebuttons (136) provide one merely illustrative example of how this may beaccomplished, it may be desirable to provide alternative components andconfigurations to accomplish a substantially similar goal. Variousmerely illustrative examples of such alternatives are described ingreater detail below.

Some instances may also call for enabling activation of the transducerand blade at two or more ultrasonic power settings (e.g., where theamplitude, frequency, and/or other ultrasonic vibration parameters arevaried). It may therefore be desirable to enable the operator to selectamong two or more ultrasonic power settings. Continuing with the premiseof enhanced ergonomics, it may be further desirable to enable such powerselection in the same way regardless of the angular orientation (aboutthe longitudinal axis of the waveguide and the handle assembly) at whichthe handle assembly is positioned in the operator's hand. In otherwords, it may be desirable to enable the operator to select fromdifferent power settings or modes regardless of the angular orientationat which the operator happens to be grasping the handle assembly at thatmoment. The below discussion provides several merely illustrativeexamples of how such enhanced power mode selection may be provided.

While various alternative housing assemblies are described below asproviding the above described features and functionality, it should beunderstood that other examples will be apparent to those of ordinaryskill in the art in view of the teachings herein. It should be furtherunderstood that various features and/or structures of the housingassemblies described herein by be readily incorporated into otherhousing assemblies described herein.

FIG. 3 schematically shows an exemplary circuit (210) that may beincorporated into instrument (120) described above and/or any otherinstruments (20) described herein. Generally, circuit (210) isconfigured to provide multiple operator inputs to permit an operator toactivate blade (152) at varying ultrasonic power levels. Circuit (210)of the present example comprises two operator inputs in the form ofswitches (212, 214). Each switch (212, 214) corresponds to a highultrasonic power level and a low ultrasonic power level for blade (152).However, in other examples circuit (210) includes any suitable number ofoperator inputs corresponding to any suitable number of ultrasonic powerlevels. Although switches (212, 214) are shown schematically, it shouldbe understood that switches (212, 214) may take on any suitable form.For instance, as will be described in greater detail below, in onemerely exemplary embodiment each switch (212, 214) comprises a circularring disposed about a handle assembly that may be similar to handleassembly (130) described above. In other examples, switches (212, 214)may take on any suitable form as will be apparent to those of ordinaryskill in the art in view of the teachings herein.

Each switch (212, 214) is in communication with a circuit board (216)via a respective wire loop (213, 215) corresponding to each switch (212,214). Generally, circuit board (216) is configured to receive inputsignals from each switch (212, 214) and communicate such signals toother components of instrument (120). In the present example, circuitboard (216) is in communication with handle assembly (130) of instrument(120) via a pair of wires (217). Wires (217) continue through handleassembly (130) to generator (12). Although circuit board (216) of thepresent example is shown as being in communication with both handleassembly (130) and generator (12), it should be understood that in otherexamples circuit board (216) is only in communication with generator(12). Indeed, in some examples circuit (210) is fully integrated intohandle assembly (130) such that circuit board (216) communicatesdirectly with generator (12) from handle assembly (130).

In the present example, circuit board (216) is configured for theprocessing of low voltage singles. In use, low voltage is used withswitches (212, 214) to provide operator inputs. Circuit board (216) thenrelays the operator inputs to generator (12). Generator (12) isconfigured to receive such inputs and apply a predetermined voltage tohandle assembly (130) via cable (14), which is shown as a plurality ofwires. The particular predetermined voltage used may be any suitablevoltage. Additionally, generator (12) may be configured to provide aplurality of predetermined voltages in repose to receiving a particularsignal from circuit board (216). For instance, actuation of switch (212)may generate a first signal and actuation of switch (214) may generate asecond signal. Upon receipt of the first signal, generator (12) mayoutput a first predetermined voltage to handle assembly (130).Similarly, upon receipt of the second signal, generator (12) may outputa second predetermined voltage to handle assembly (130). First andsecond voltages of the present example may correspond to a transducersupplying different ultrasonic power levels to blade (152).

While voltage is used to describe the electrical signal communicatedfrom generator (12) to handle assembly (130) it should be understoodthat any other characteristic of the electronic signal (e.g., power,current, frequency, amplitude, etc.) may be changed in response toactuation of switches (212, 214). It should also be understood thatcircuit board (216) may take on any suitable form such as an analog ordigital signal processing mechanism. Additionally, circuit board (216)may include any components suitable for processing electric signalsbetween switches (212, 214) and generator (12). In other examples,circuit (210) may take on any other suitable form as will be apparent tothose of ordinary skill in the art in view of the teachings herein.

A. Exemplary Alternative Handle Assembly with Central Electrical Contact

FIG. 4 shows an exemplary alternative handle assembly (310) that may bereadily incorporated into ultrasonic instrument (120) described above.Handle assembly (310) is substantially the same as handle assembly (130)described above, unless otherwise described herein. For instance, handleassembly (310) comprises a tubular elongate body (312) defined by twomating housing portions (314, 316). Like with handle assembly (130),handle assembly (310) supports shaft assembly (140), which includes anouter sheath projecting from the distal end of handle assembly (310).

Unlike handle assembly (130), handle assembly (310) comprises a buttonassembly (320), which includes two discrete ring shaped buttons (322,324) extending angularly around body (312) near the distal end of body(312). As will be described in greater detail below, each button (322,324) is configured to be actuated radially inwardly from any anglearound the perimeter of body (312), thereby laterally displacing theentire button (322, 324) relative to the central longitudinal axis ofhandle assembly (310), to activate blade (152) at one of two discretepower levels. Unlike buttons (136) described above, each button (322,324) extends continuously about the perimeter of body (312). Moreover,each button (322, 324) has a discrete function in contrast to buttons(136), which all have an identical function. In the present example,each button (322, 324) is rigid such that button (322, 324) will notdeform (but will move as a rigid unit) in response to an operatorpressing radially inwardly against button (322, 324). In some otherversions, at least a portion of each button (322, 324) may bedeformable.

FIG. 5 shows the internal components of handle assembly (310). As can beseen, handle assembly (310) of the present example is equipped with anultrasonic transducer (126), which is received within a cavity (318)defined by body (312). Transducer (126) is coupled to waveguide (148) ofshaft assembly (140) such that transducer (126) may communicateultrasonic vibrations to waveguide (148), thereby powering ultrasonicblade (152). By way of example only, suitable coupling features betweentransducer (126) and waveguide may be provided in accordance with atleast some of the teachings of U.S. Ser. No. 14/515,129, entitled“Activation Features for Ultrasonic Surgical Instrument,” filed Oct. 15,2014, issued as U.S. Pat. No. 9,907,565 on Mar. 6, 2018; U.S. Pub. No.2015/0148829, entitled “Methods and Features for Coupling UltrasonicSurgical Instrument Components Together,” published May 28, 2015, issuedas U.S. Pat. No. 10,226,271 on Mar. 12, 2019; and U.S. Pat. No.8,152,825, entitled “Medical Ultrasound System and Handpiece and Methodsfor Making and Tuning,” issued Apr. 10, 2012, the disclosure of which isincorporated by reference herein.

Button assembly (320) is disposed coaxially about shaft assembly (140)at the distal end of body (312). Button assembly (320) comprises aproximal button (322), a distal button (324), and an alignment assembly(330). As described above, each button (322, 324) is generally ringshaped. The inside proximal diameter of each button (322, 324) includesa frustoconical cam feature (326, 328). As will be described in greaterdetail below, each cam feature (326, 328) is configured to engage withalignment assembly (330) to resiliently bias each button (322, 324)toward a position that is generally coaxial with shaft assembly (140).

Alignment assembly (330) comprises a separate alignment mechanism (332,336) corresponding to each button (322, 324). Each alignment mechanism(332, 336) comprises a plurality of longitudinally translatable cammembers (334, 338), which are resiliently biased distally bycorresponding springs (335, 339). The distal end of each cam member(334, 338) is shaped to complement the frustoconical cam feature (326,328) of the corresponding button (322, 324). Thus, as will be describedin greater detail below, each cam member (334, 338) is configured toengage its corresponding button (322, 324) to resiliently bias thecorresponding button (322, 324) toward a radial position of coaxialalignment with shaft assembly (140).

FIG. 6 shows a cross-section of button assembly (320) with thecross-section taken through proximal button (322). As can be seen,button (322) includes a plurality of inner channels (325) orientedaround the inner diameter of button (322). Each channel (325) isconfigured to receive a single cam member (338), such that cam members(338) can pass through button (322) to button (324) without impactingmovement of button (322). Thus, in the present example, cam members(338) comprise a plurality of discrete cam members (338) that worktogether to bias button (324). Although not explicitly shown, it shouldbe understood that cam members (334) are similarly configured in thepresent example. While cam members (334, 338) are shown and describedherein as comprising a plurality of discrete elements, it should beunderstood that no such limitation is intended. Indeed, in some exampleseach cam member (334, 338) may comprise a single discrete tubularelement rather than a plurality of discrete elements. As will bedescribed in greater detail below, some cam member (334, 338)configurations may be more or less desirable depending on the particularconfiguration of buttons (322, 324).

While not shown, it should also be understood that handle assembly (310)may include guide features that are configured to permit each cam member(334, 338) to translate longitudinally; yet prevent each cam member(334, 338) from deflecting laterally relative to the longitudinal axisof shaft assembly (140). Such guide features may comprise one or morechannels and bosses formed in body (312), one or more chassis componentsthat are coupled with body (312), and/or any other suitable componentsor configurations. Various suitable components and configurations thatmay be used to guide each cam member (334, 338) will be apparent tothose of ordinary skill in the art in view of the teachings herein.

As shown in FIG. 6, button (322) includes a wire (342) disposed therein.Wire (342) is coupled to a plurality of discrete electrically conductivecontacts (344), which are disposed about the inner diameter of button(322). Although not shown, it should be understood that wire (342) isconnected to a circuit board similar to circuit board (216) describedabove. As will be described in greater detail below, such a connectionis configured to permit button (322) to complete an activation circuit,which activates blade (152) at a particular ultrasonic power level.

Conductive contacts (344) of the present example are spaced evenly aboutthe inner diameter of proximal button (322). As will be understood, thepositioning of contacts (344) permits proximal button (322) to makeelectrical contact with outer sheath (142) of shaft assembly (140) whenproximal button (322) is moved radially inwardly toward outer sheath(142) from a variety of angular positions about the longitudinal axis ofshaft assembly (140). Although the present example is shown as having aplurality of contacts (344), it should be understood that in otherexamples contact (344) may take on other forms or configurations. Forinstance, in one alternative example proximal button (322) includes asingle electrical contact comprising an electrically conductive traceextending around the inner diameter of proximal button (322). In otherexamples, proximal button (322) may include any other suitableconductive contact (344) positioning as will be apparent to those ofordinary skill in the art in view of the teachings herein.

Although not shown, it should be understood that button (324) includesconductive contacts similar to conductive contacts (344) described abovewith respect to button (322). Similarly, button (324) is also equippedwith a wire that is similar to wire (342) described above. However,unlike wire (342), the wire of button (324) is configured to complete aseparate activation circuit when the conductive contacts of button (324)are brought into contact with outer sheath (142). As will be describedin greater detail below, this permits distal button (324) to activateblade (152) at a different level of power than the level of poweractivated by proximal button (322).

As described above, each button (322, 324) is associated with acorresponding activation circuit. In the present example, the oppositelead of each activation circuit is in communication with outer sheath(142). As can be seen in FIG. 6, the portion of outer sheath (142)positioned interior to buttons (322, 324) comprises a conductivemetallic material. Because of the conductive properties of this regionof outer sheath (142), when either button (322, 324) is moved intocontact with outer sheath (142), the corresponding activation circuit iscompleted as an electrical signal is communicated through outer sheath(142). Thus, outer sheath (142) of the present example acts as anelectrical conductor to complete either activation circuit associatedwith each button (322, 324).

In some examples, it may be desirable for outer sheath (142) to benon-conductive or otherwise not be configured to carry an electricalcharge. Thus, in some examples outer sheath (142) includes an electricaltrace printed or otherwise disposed on the outer diameter of outersheath (142). In examples utilizing such an electrical trace, theelectrical trace may include rings around outer sheath at a longitudinalposition along outer sheath (142) corresponding to conductive contacts(344) of proximal button (322) and the conductive contacts of distalbutton (324). Alternatively, in some examples, two traces may be usedwith one trace corresponding to each button (322, 324), rather than asingle common trace for each button (322, 324). In still other examples,outer sheath (142) may be equipped with wires and conductors assimilarly described above with respect to proximal button (322).

FIGS. 7-9 depict an exemplary use of handle assembly (310) to activateblade (152) with ultrasonic energy and varying degrees of power. As canbe seen in FIG. 7, buttons (322, 324) of button assembly (320) initiallybegin in a neutral position. In the neutral position, each alignmentmechanism (332, 336) of alignment assembly (330) generally acts on eachcorresponding button (322, 324) to laterally position each button (322,324) such that each button (322, 324) is coaxially aligned with shaftassembly (140). In particular, each cam member (334, 338) is resilientlybiased distally by each cam member's (334, 338) respective spring (335,339). The distal end of each cam member (334, 338) in turn acts on camfeature (326, 328) of each respective button (322, 324). This engagementbetween cam members (334, 338) and cam features (326, 328) generates anoutwardly oriented force on buttons (322, 324). This outwardly orientedforce is uniform about the entire circumference of each cam member (334,338). Thus, because cam members (334, 338) extend along a full circlewithin the inner diameter associated with button (322, 324), the netforce resiliently biases each button (322, 324) laterally toward aposition that is coaxial with the central longitudinal axis of shaftassembly (140).

When both buttons (322, 324) are in the neutral position, there is nocontact between either button (322, 324) and shaft assembly (140). Theactivation circuits associated with buttons (322, 324) are thereforeboth in an open circuit state. When each activation circuit is in theopen circuit state, blade (152) is inactive and not ultrasonicallyenergized.

To activate blade (152) via proximal button (322), an operator may pushproximal button (322) toward the central longitudinal axis of shaftassembly (140). As can be seen in FIG. 8, the force is shown as beingapplied to an upper portion of proximal button (322). However, it shouldbe understood that an operator may apply a similar force at any pointaround the outer diameter of proximal button (322) to achieve the sameresult of activating blade (152) at the power level associated withproximal button (322).

As proximal button (322) is pressed by an operator, proximal button(322) moves laterally relative to body (312) of handle assembly (310)such that proximal button (322) is displaced from the initial coaxialalignment with shaft assembly (140). The force applied by an operator issufficient to overcome the resilient bias supplied by spring (335).Thus, as proximal button (322) is displaced laterally, cam member (334)is driven proximally by the frustoconical shape of cam feature (326).

Continued lateral displacement of proximal button (322) will eventuallyresult in physical contact between at least a portion of the innerdiameter of proximal button (322) and the outer diameter of outer sheath(142) of shaft assembly (140). Because of channels (325) in proximalbutton (322), movement toward shaft assembly (140) is not impeded by cammembers (338) associated with distal button (324). Once contact is madebetween proximal button (322) and outer sheath (142) of shaft assembly(140), electrical contact is made between contacts (344) of proximalbutton (322) and outer sheath (142). With such electrical contact, theactivation circuit associated with proximal button (322) is completedand thereby transitioned to a closed circuit state. With the circuitassociated with proximal button (322) in a closed circuit state, blade(152) is activated at a first predetermined power level. In someversions, this first power level is a relatively low power level.

It should be understood that activation of blade (152) may beaccomplished as similarly described above with respect to circuit (210).For example, the activation circuit associated with proximal button(322) may be a low voltage circuit in communication with a circuitboard, similar to circuit board (216), which may in turn be incommunication with to a generator that powers blade (152) via transducer(126) via waveguide (148).

Once an operator desires to deactivate blade (152) from the power levelassociated with proximal button (322), the operator may release proximalbutton (322). Alignment assembly (330) may then return proximal button(322) to the neutral position as described above with respect to FIG. 7.

To activate blade (152) via distal button (324), an operator may pushdistal button (324) toward the central longitudinal axis of shaftassembly (140). As can be seen in FIG. 9, the force is shown as beingapplied to an upper portion of distal button (324). However, it shouldbe understood that an operator may apply a similar force at any pointaround the outer diameter of distal button (324) to achieve the sameresult of activating blade (152) at the power level associated withdistal button (324).

As distal button (324) is pressed by an operator, distal button (324)moves laterally relative to body (312) of handle assembly (310) suchthat distal button (324) is displaced from the initial coaxial alignmentwith shaft assembly (140). The force applied by an operator issufficient to overcome the resilient bias supplied by spring (339).Thus, as distal button (324) is displaced laterally, cam member (338) isdriven proximally by the frustoconical shape of cam feature (328).

Continued displacement of distal button (324) will eventually result inphysical contact between at least a portion of the inner diameter ofdistal button (324) and the outer diameter of outer sheath (142) ofshaft assembly (140). Once contact is made between distal button (324)and outer sheath (142) of shaft assembly (140), electrical contact ismade between the contacts of distal button (324) and outer sheath (142).With such electrical contact, the activation circuit associated withdistal button (324) is completed and thereby transitioned to a closedcircuit state. With the circuit associated with distal button (324) in aclosed circuit state, blade (152) is activated at a second predeterminedpower level. In some versions, this second power level is a relativelyhigh power level.

It should be understood that activation of blade (152) may beaccomplished as similarly described above with respect to circuit (210).For example, the activation circuit associated with distal button (324)may be a low voltage circuit in communication with a circuit board,similar to circuit board (216), which may in turn be in communicationwith to a generator that powers blade (152) via transducer (126) viawaveguide (148).

Once an operator desires to switch power levels, or otherwise deactivateblade (152) at the power level associated with distal button (324), theoperator may release distal button (324). Alignment assembly (330) maythen return distal button (324) to the neutral position as describedabove with respect to FIG. 7.

B. Exemplary Alternative Handle Assembly with Discrete ElectricalContacts

FIG. 10 shows another exemplary alternative handle assembly (410) thatmay be readily incorporated into ultrasonic instrument (120) describedabove. Handle assembly (410) is substantially the same as handleassembly (130) described above, unless otherwise described herein. Forinstance, handle assembly (410) comprises a tubular elongate body (412)defined by two mating housing portions (414, 416). Like with handleassembly (130), handle assembly (410) supports shaft assembly (140),which includes an outer sheath projecting from the distal end of handleassembly (410).

Unlike handle assembly (130), handle assembly (410) comprises a buttonassembly (420), which includes two discrete ring shaped buttons (422,424) extending angularly around body (412) near the distal end of body(412). As will be described in greater detail below, each button (422,424) is configured to be actuated radially inwardly from any anglearound the perimeter of body (412), thereby laterally displacing theentire button (422, 424) relative to the central longitudinal axis ofhandle assembly (410), to activate blade (152) at one of two discretepower levels. Unlike buttons (136) described above, each button (422,424) is continuous about the perimeter of body (412). Moreover, eachbutton (422, 424) has a discrete function in contrast to buttons (136),which have an identical function. In the present example, each button(422, 424) is rigid such that button (422, 424) will not deform (butwill move as a rigid unit) in response to an operator pressing radiallyinwardly against button (422, 424). In some other versions, at least aportion of each button (422, 424) may be deformable.

FIG. 11 shows the internal components of handle assembly (410). As canbe seen, handle assembly (410) of the present example is equipped withan ultrasonic transducer (126), which is received within a cavity (418)defined by body (412). Transducer (126) is coupled to waveguide (148) ofshaft assembly (140) such that transducer (126) may communicateultrasonic vibrations to waveguide (148), thereby powering ultrasonicblade (152). By way of example only, suitable coupling features betweentransducer (126) and waveguide may be provided in accordance with atleast some of the teachings of U.S. Ser. No. 14/515,129, entitled“Activation Features for Ultrasonic Surgical Instrument,” filed Oct. 15,2014, issued as U.S. Pat. No. 9,907,565 on Mar. 6, 2018; U.S. Pub. No.2015/0148829, entitled “Methods and Features for Coupling UltrasonicSurgical Instrument Components Together,” published May 28, 2015, issuedas U.S. Pat. No. 10,226,271 on Mar. 12, 2019; and U.S. Pat. No.8,152,825, entitled “Medical Ultrasound System and Handpiece and Methodsfor Making and Tuning,” issued Apr. 10, 2012, the disclosure of which isincorporated by reference herein.

Button assembly (420) is disposed coaxially about shaft assembly (140)at the distal end of body (412). Button assembly (420) comprises aproximal button (422), a distal button (424), and an alignment assembly(430). As described above, each button (422, 424) is generally ringshaped. The inside proximal diameter of each button (422, 424) includesa frustoconical cam feature (426, 428). As will be described in greaterdetail below, each cam feature (426, 428) is configured to engage withalignment assembly (430) to resiliently bias each button (422, 424)toward a position that is generally coaxial with shaft assembly (140).

Alignment assembly (430) comprises a separate alignment mechanism (432,436) corresponding to each button (422, 424). Each alignment mechanism(432, 436) comprises a plurality of longitudinally translatable cammembers (434, 438), which are resiliently biased distally bycorresponding springs (435, 439). The distal end of each cam member(434, 438) is shaped to correspond to the frustoconical cam feature(426, 428) of the corresponding button (422, 424). Thus, as will bedescribed in greater detail below, each cam member (434, 438) isconfigured to engage its corresponding button (422, 424) to resilientlybias the corresponding button (422, 424) toward a radial position ofcoaxial alignment with shaft assembly (140).

FIG. 12 shows a cross-section of button assembly (420) with thecross-section taken through proximal button (422). Unlike proximalbutton (322) of handle assembly (310) described above, proximal button(422) of the present example omits inner channels (325). Instead,proximal button (422) includes a substantially solid inner diameter thatis configured to directly contact the cam member (438) that isassociated with distal button (424), as will be described in greaterdetail below. Similarly, cam member (438) of the present examplecomprises a single tubular member, rather than a plurality of discretemembers. Although not explicitly shown, it should be understood that cammember (434) is similarly configured in the present example. While cammembers (434, 438) are shown and described herein as comprising a singletubular element, it should be understood that no such limitation isintended. Indeed, in some examples each cam member (434, 438) mayinstead comprise a plurality of discrete elements, much like cam members(334, 338) described above.

As can also be seen in FIG. 12, proximal button (422) includes aconductive coating (442) adhered or otherwise secured to the innerdiameter of proximal button (422). Coating (442) comprises a thin filmof electrically conductive material that extends around the entire innerdiameter of proximal button (422). Although not shown, it should beunderstood that coating (442) is connected to one or more wires ortraces that are in communication with a circuit board similar to circuitboard (216) described above. Cam member (438) similarly includes aconductive coating (444). As will be described in greater detail below,such a connection is configured to permit proximal button (422) tocomplete an activation circuit when brought into contact with cam member(438), which activates blade (152) at a particular ultrasonic powerlevel.

Although not shown, it should be understood that distal button (424)includes conductive coating similar to coating (442) described abovewith respect to proximal button (422). Similarly, distal button (424) isalso equipped with a wire that is similar to the wire or traceassociated with proximal button (422) described above. However, unlikethe wire associated with proximal button (422), the wire of distalbutton (424) is configured to complete a separate activation circuitwhen the coating of distal button (424) is brought into contact withouter sheath (142). As will be described in greater detail below, thispermits distal button (424) to activate blade (152) at a different levelof power than the level of power activated by proximal button (422).

As described above, each button (422, 424) is associated with acorresponding activation circuit. In the present example, the oppositelead of each activation circuit is in communication with conductivecoating (444) of cam member (438) or outer sheath (142). In particular,for the activation circuit associated with proximal button (422), theopposite lead is in communication with conductive coating (444) of cammember (438). Correspondingly, the activation circuit associated withdistal button (424) is in communication with outer sheath (142). As canbe seen in FIG. 12, outer sheath (142) comprises a conductive metallicmaterial. Because of the conductive properties of outer sheath (142),when distal button (424) is moved into contact with outer sheath (142)the corresponding activation circuit is completed as an electricalsignal is communicated through outer sheath (142). Thus, outer sheath(142) of the present example acts as an electrical conductor to completethe activation circuit associated with distal button (424).

In some examples, it may be desirable for outer sheath (142) to benon-conductive or otherwise not be configured to carry an electricalcharge. Thus, in some examples outer sheath (142) includes an electricaltrace printed or otherwise disposed on the outer diameter of outersheath (142). In examples utilizing such an electrical trace, theelectrical trace may include rings around outer sheath at a longitudinalposition along outer sheath (142) corresponding to the conductivecoating of distal button (424). In other examples, outer sheath (142)may be equipped with wires and conductors as described above withrespect to proximal button (322) of handle assembly (310).

FIGS. 13-15 depict an exemplary use of handle assembly (410) to activateblade (152) with ultrasonic energy and varying degrees of power. As canbe seen in FIG. 13, buttons (422, 424) of button assembly (420)initially begin in a neutral position. In the neutral position, eachalignment mechanism (432, 436) of alignment assembly (430) generallyacts on each corresponding button (422, 424) to laterally position eachbutton (422, 424) such that each button (422, 424) is coaxially alignedwith shaft assembly (140). In particular, each cam member (434, 438) isresiliently biased distally by each cam member's (434, 438) respectivespring (435, 439). The distal end of each cam member (434, 438) in turnacts on cam feature (426, 428) of each respective button (422, 424).This engagement between cam members (434, 438) and cam features (426,428) generates an outwardly oriented force on buttons (422, 424). Thisoutwardly oriented force is uniform about the entire circumference ofeach cam member (434, 438). Thus, because cam members (434, 438) extendalong a full circle within the inner diameter associated with button(422, 424), the net force resiliently biases each button (422, 424)laterally toward a position that is coaxial with the centrallongitudinal axis of shaft assembly (140).

When proximal button (422) is in the neutral position, there is nocontact between proximal button (422) and cam member (438). Likewise,when distal button (424) is in the neutral position, there is no contactbetween distal button (424) and shaft assembly (140). Thus theactivation circuits associated with buttons (422, 424) are in an opencircuit state. When each activation circuit is in the open circuitstate, blade (152) is inactive and not ultrasonically energized.

To activate blade (152) via proximal button (422), an operator may pushproximal button (422) toward the central longitudinal axis of shaftassembly (140). As can be seen in FIG. 14, the force is shown as beingapplied to an upper portion of proximal button (422). However, it shouldbe understood that an operator may apply a similar force at any pointaround the outer diameter of proximal button (422) to achieve the sameresult of activating blade (152) at the power level associated withproximal button (422).

As proximal button (422) is pressed by an operator, proximal button(422) moves laterally relative to body (412) of handle assembly (410)such that proximal button (422) is displaced from the initial coaxialalignment with shaft assembly (140). The force applied by an operator issufficient to overcome the resilient bias supplied by spring (435).Thus, as proximal button (422) is displaced laterally, cam member (434)is driven proximally by the frustoconical shape of cam feature (426).

Continued lateral displacement of proximal button (422) will eventuallyresult in physical contact between at least a portion of coating (442)of the inner diameter of proximal button (422) and coating (444) of theouter diameter of cam member (438). Once contact is made between coating(442) of proximal button (322) and coating (444) of cam member (438),electrical contact is made. With such electrical contact, the activationcircuit associated with proximal button (422) is completed and therebytransitioned to a closed circuit state. With the activation circuitassociated with proximal button (422) in a closed circuit state, blade(152) is activated at a first predetermined power level. In someversions, this first power level is a relatively low power level.

It should be understood that activation of blade (152) may beaccomplished as similarly described above with respect to circuit (210).For example, the activation circuit associated with proximal button(422) may be a low voltage circuit in communication with a circuitboard, similar to circuit board (216), which may in turn be incommunication with to a generator that powers blade (152) via transducer(126) via waveguide (148).

Once an operator desires to deactivate blade (152) from the power levelassociated with proximal button (422), the operator may release proximalbutton (422). Alignment assembly (430) may then return proximal button(422) to the neutral position as described above with respect to FIG.13.

To activate blade (152) via distal button (424), an operator may pushdistal button (424) toward the central longitudinal axis of shaftassembly (140). As can be seen in FIG. 15, the force is shown as beingapplied to an upper portion of distal button (424). However, it shouldbe understood that an operator may apply a similar force at any pointaround the outer diameter of distal button (424) to achieve the sameresult of activating blade (152) at the power level associated withdistal button (424).

As distal button (424) is pressed by an operator, distal button (424)moves laterally relative to body (412) of handle assembly (410) suchthat distal button (424) is displaced from the initial coaxial alignmentto shaft assembly (140). The force applied by an operator is sufficientto overcome the resilient bias supplied by spring (439). Thus, as distalbutton (424) is displaced laterally, cam member (438) is drivenproximally by the frustoconical shape of cam feature (428).

Continued displacement of distal button (424) eventually will result inphysical contact between at least a portion of the inner diameter ofdistal button (424) and the outer diameter of outer sheath (142) ofshaft assembly (140). Once contact is made between distal button (424)and outer sheath (142) of shaft assembly (140), electrical contact ismade between the coating of distal button (424) and outer sheath (142).With such electrical contact, the activation circuit associated withdistal button (424) is completed and thereby transitioned to a closedcircuit state. With the activation circuit associated with distal button(424) in a closed circuit state, blade (152) is activated at a secondpredetermined power level. In some versions, this second power level isa relatively high power level.

It should be understood that activation of blade (152) may beaccomplished as similarly described above with respect to circuit (210).For example, the activation circuit associated with distal button (424)may be a low voltage circuit in communication with a circuit board,similar to circuit board (216), which may in turn be in communicationwith to a generator that powers blade (152) via transducer (126) viawaveguide (148).

Once an operator desires to switch power levels, or otherwise deactivateblade (152) at the power level associated with distal button (424), theoperator may release distal button (424). Alignment assembly (430) maythen return distal button (424) to the neutral position as describedabove with respect to FIG. 13.

C. Exemplary Alternative Handle Assembly with Internal Contact Switches

FIG. 16 shows still another exemplary alternative handle assembly (510)that may be readily incorporated into ultrasonic instrument (120)described above. Handle assembly (510) is substantially the same ashandle assemblies (310, 410) described above, unless otherwise describedherein. For instance, handle assembly (510) comprises a tubular elongatebody (512). Like with handle assemblies (310, 410), handle assembly(510) supports shaft assembly (140), which includes an outer sheathprojecting from the distal end of handle assembly (410).

Also like handle assemblies (310, 410), handle assembly (510) comprisesa button assembly (520), which includes two discrete ring shaped buttons(522, 524) extending angularly around body (512) near the distal end ofbody (512). As will be described in greater detail below, each button(522, 524) is configured to be actuated radially inwardly from any anglearound the perimeter of body (512) to activate blade (152) at one of twodiscrete power levels. Each button (522, 424) extends continuously aboutthe perimeter of body (512). Moreover, each button (522, 524) has adiscrete function in contrast to buttons (136), which have an identicalfunction. In the present example, each button (522, 524) is rigid suchthat button (522, 524) will not deform (but will move as a rigid unit)in response to an operator pressing radially inwardly against button(522, 524). In some other versions, at least a portion of each button(522, 524) may be deformable.

Button assembly (520) is disposed coaxially about shaft assembly (140)at the distal end of body (512). Button assembly (520) comprises aproximal button (522), a distal button (524), and an alignment assembly(530). As described above, each button (522, 524) is generally ringshaped. The inside proximal diameter of each button (522, 524) includesa frustoconical cam feature (526, 528). As will be described in greaterdetail below, each cam feature (526, 528) is configured to engage withalignment assembly (530) to resiliently bias each button (522, 524)toward a position that is generally coaxial with shaft assembly (140).

Alignment assembly (530) comprises a separate alignment mechanism (532,536) corresponding to each button (522, 524). Each alignment mechanism(532, 536) comprises a plurality of longitudinally translatable cammembers (534, 538), which are resiliently biased distally bycorresponding springs (535, 539). The distal end of each cam member(534, 538) is shaped to complement the frustoconical cam feature (526,528) of the corresponding button (522, 524). Thus, as will be describedin greater detail below, each cam member (534, 538) is configured toengage its corresponding button (522, 524) to resiliently bias thecorresponding button (522, 524) toward a radial position of coaxialalignment with shaft assembly (140).

Unlike handle assemblies (310, 410) described above, handle assembly(510) does not utilize the internal diameter of buttons (522, 524) toactivate blade (152). Instead, alignment assembly (530) is used toactuate contact switches (542, 544) mounted within body (512). Inparticular, handle assembly (510) comprises two contact switches (542,544). Each contact switch (542, 544) corresponds to a particular button(522, 524). In the present example, contact switch (542) corresponds toproximal button (522), while contact switch (544) corresponds to distalbutton (524). Each contact switch (542, 544) is in communication with arespective set of wires (543, 545) that extend through body (512).Contact switches (542, 544) together with wires (543, 545) form twoindependent activation circuits that correspond to each button (522,524).

Each contact switch (542, 545) is actuated using a corresponding cammember (534, 538). In particular, each cam member (534, 538) includes aproximally extending protrusion (552, 554). As will be described ingreater detail below, each protrusion (542, 544) is configured to extenda distance proximally within body (512) to permit each protrusion (552,554) to contact its corresponding contact switch (542, 544) when eachrespective cam member (534, 538) is driven proximally by each respectivebutton (522, 524).

FIGS. 16-18 depict an exemplary use of handle assembly (510) to activateblade (152) with ultrasonic energy and varying degrees of power. As canbe seen in FIG. 16, buttons (522, 524) of button assembly (520)initially begin in a neutral position. In the neutral position, eachalignment mechanism (532, 536) of alignment assembly (530) generallyacts on each corresponding button (522, 524) to align each button (522,524) coaxially with shaft assembly (140). In particular, each cam member(534, 538) is resiliently biased distally by each cam member's (534,538) respective spring (535, 539). The distal end of each cam member(534, 538) in turn acts on cam feature (526, 528) of each respectivebutton (522, 524). This engagement between cam members (534, 538) andcam features (526, 528) generates an outwardly oriented force on buttons(522, 524). This outwardly oriented force is uniform about the entirecircumference of each cam member (534, 538). Thus, because cam members(534, 538) extend along a full circle within the inner diameterassociated with button (522, 524), the net force resiliently biases eachbutton (522, 524) laterally toward a position that is coaxial with thecentral longitudinal axis of shaft assembly (140).

When proximal button (522) is in the neutral position, cam member (534)is disposed distally and there is no contact between protrusion (552)and contact switch (542). Likewise, when distal button (524) is in theneutral position, cam member (538) is disposed distally and there is nocontact between protrusion (554) and contact switch (544). Thus theactivation circuits associated with buttons (422, 424) are in an opencircuit state. When each activation circuit is in the open circuitstate, blade (152) is inactive and not ultrasonically energized.

To activate blade (152) via proximal button (522), an operator may pushproximal button (522) toward the central longitudinal axis of shaftassembly (140). As can be seen in FIG. 17, the force is shown as beingapplied to an upper portion of proximal button (522). However, it shouldbe understood that an operator may apply a similar force at any pointaround the outer diameter of proximal button (522) to achieve the sameresult of activating blade (152) at the power level associated withproximal button (522).

As proximal button (522) is pressed by an operator, proximal button(522) moves laterally relative to body (512) of handle assembly (510)such that proximal button (522) is displaced from the initial coaxialalignment with shaft assembly (140). The force applied by an operator issufficient to overcome the resilient bias supplied by spring (535).Thus, as proximal button (522) is displaced laterally, cam member (434)is driven proximally by the frustoconical shape of cam feature (526).

Continued displacement of proximal button (522) will eventually resultin physical contact between protrusion (552) of cam member (534) andcontact switch (542). Once contact is made between protrusion (552) ofcam member (534) and contact switch (542), the activation circuitassociated with proximal button (522) is completed and therebytransitioned to a closed circuit state. With the activation circuitassociated with proximal button (522) in a closed circuit state, blade(152) is activated at a first predetermined power level. In someversions, this first power level is a relatively low power level.

It should be understood that activation of blade (152) may beaccomplished as similarly described above with respect to circuit (210).For example, the activation circuit associated with proximal button(522) may be a low voltage circuit in communication with a circuitboard, similar to circuit board (216), which may in turn be incommunication with to a generator that powers blade (152) via transducer(126) via waveguide (148).

Once an operator desires to deactivate blade (152) from the power levelassociated with proximal button (522), the operator may release proximalbutton (522). Alignment assembly (530) may then return proximal button(522) to the neutral position as described above with respect to FIG.16.

To activate blade (152) via distal button (524), an operator may pushdistal button (524) toward the central longitudinal axis of shaftassembly (140). As can be seen in FIG. 18, the force is shown as beingapplied to an upper portion of distal button (524). However, it shouldbe understood that an operator may apply a similar force at any pointaround the outer diameter of distal button (524) to achieve the sameresult of activating blade (152) at the power level associated withdistal button (524).

As distal button (524) is pressed by an operator, distal button (524)moves laterally relative to body (512) of handle assembly (510) suchthat distal button (524) is displaced from the initial coaxial alignmentwith shaft assembly (140). The force applied by an operator issufficient to overcome the resilient bias supplied by spring (539).Thus, as distal button (524) is displaced laterally, cam member (538) isdriven proximally by the frustoconical shape of cam feature (528).

Continued displacement of distal button (524) eventually will result inphysical contact between protrusion (554) of cam member (538) andcontact switch (544). Once contact is made between protrusion (554) ofcam member (538) and contact switch (544), the activation circuitassociated with distal button (524) is completed and therebytransitioned to a closed circuit state. With the circuit associated withdistal button (524) in a closed circuit state, blade (152) is activatedat a second predetermined power level. In some versions, this secondpower level is a relatively high power level.

It should be understood that activation of blade (152) may beaccomplished as similarly described above with respect to circuit (210).For example, the activation circuit associated with distal button (524)may be a low voltage circuit in communication with a circuit board,similar to circuit board (216), which may in turn be in communicationwith to a generator that powers blade (152) via transducer (126) viawaveguide (148).

Once an operator desires to switch power levels, or otherwise deactivateblade (152) at the power level associated with distal button (524), theoperator may release distal button (524). Alignment assembly (530) maythen return distal button (524) to the neutral position as describedabove with respect to FIG. 16.

IV. Exemplary Button Lock Features

In some instances it may be desirable to lock out actuation ofactivation features of a handle assembly similar to handle assemblies(310, 410, 510) described above. For instance, with a set of buttonssimilar to buttons (322, 324, 422, 424, 522, 524) described above soaccessible to an operator, inadvertent activation may be possible.Accordingly, it may be desirable to incorporate features into a handleassembly to prevent inadvertent activation or otherwise lock out theinstrument. While various additional handle assembly features aredescribed below, it should be understood that other examples will beapparent to those of ordinary skill in the art in view of the teachingsherein. It should be further understood that to the extent that thevarious features and/or structures are described with respect to aparticular handle assembly, the same features and/or structures may bereadily incorporated into other handle assemblies described herein.

A. Exemplary Removable Insert Lock Feature

FIG. 19 shows handle assembly (310), described above, equipped with anexemplary lock sleeve (610). Lock sleeve (610) is generally configuredto prevent actuation of buttons (322, 324) of handle assembly (310), aswill be described in greater detail below. Lock sleeve (610) comprises asingle polycarbonate or other electrically insulating material. Locksleeve (610) is shaped for insertion into a gap between shaft assembly(140) and buttons (322, 324). To accommodate the distal extension ofshaft assembly (140), lock sleeve (610) is generally donut shaped with acentral opening (612) disposed on the distal end of lock sleeve (610).The proximal end of lock sleeve is generally open to permit positioningof lock sleeve (610) over buttons (322, 324).

As can be seen in FIG. 20, lock sleeve (610) is shaped to cover buttons(322, 324) and curves around the distal end of handle assembly (310) andinto the gap between shaft assembly (140) and buttons (322, 324).Accordingly, lock sleeve (610) covers outer sheath (142) of shaftassembly (140), thereby preventing contact between outer sheath (142)and buttons (322, 324). As described above, buttons (322, 324) includeelectrical contacts (344) on their inner diameter that create a closedactivation circuit condition when contact occurs between buttons (322,324) and outer sheath (142). Thus, lock sleeve (610) prevents creationof a closed activation circuit condition by preventing contact betweenbuttons (322, 324) and outer sheath (142). Additionally, in someexamples lock sleeve (610) has a thickness suitable to preventsubstantially all lateral movements of buttons (322, 324). Therefore, insome examples lock sleeve (610) also acts as a physical stop to preventlateral movement of buttons (322, 324).

To disengage lock sleeve (610), an operator may simply pull lock sleeve(610) distally along shaft assembly (140) as shown in FIG. 21. With locksleeve (610) removed, buttons (322, 324) regain the functionalitydescribed above with respect to FIGS. 4-9. In some versions, lock sleeve(610) is pulled distally all the way off of shaft assembly (140) suchthat lock sleeve (610) is fully separated from the rest of theinstrument. In some other versions, lock sleeve (610) is simply pulleddistally enough to enable free actuation of buttons (322, 324) and isthen released, such that lock sleeve (610) remains disposed at a distalposition on shaft assembly (140).

It should also be understood that various features may be used toselectively retain the position of lock sleeve (610) in the lockingposition shown in FIG. 20. For instance, lock sleeve (610) mayresiliently bear against outer sheath (142) to provide friction thatholds lock sleeve (610) in place in the proximal position.Alternatively, an o-ring, elastomeric washer, or similar feature may bepositioned about outer sheath (142), either inside lock sleeve (610) ordistal to (but adjacent to) lock sleeve (610); and such a feature mayprovide sufficient resistance to prevent inadvertent distal movement oflock sleeve (610) while permitting intentional distal movement of locksleeve (610). Other suitable features and methods for selectivelyretaining positioning of lock sleeve (610) will be apparent to those ofordinary skill in the art in view of the teachings herein.

Although lock sleeve (610) is shown as having a particular shape, itshould be understood that lock sleeve (610) may take on numerous othershapes. For instance, in some examples lock sleeve (610) does not coverbuttons (322, 324). Instead, lock sleeve (610) extends outwardly awayfrom shaft assembly (140). Of course, numerous suitable alternativeshapes for lock sleeve (610) will be apparent to those of ordinary skillin the art in view of the teachings herein.

B. Exemplary Spring Biased Lock Feature

FIG. 22 shows handle assembly (310), described above, equipped with anexemplary lock assembly (710). Unlike lock sleeve (610) described above,lock assembly (710) is not removable. Instead, lock assembly (710) isgenerally movable by an operator to selectively lock and unlock buttons(322, 324). Lock assembly (710) comprises a grounding member (720), alock member (730), and a spring (750) disposed between grounding member(720) and lock member (730). As best seen in FIG. 23, grounding member(720) is integral with outer sheath (142) of shaft assembly (140).Alternatively, in some examples grounding member (720) may be a separatecomponent that is independent from outer sheath (142).

Grounding member (720) generally forms a longitudinally fixed platform,which restricts the motion of lock member (730) relative to body (312)of handle assembly (310). In particular, grounding member (720) definesa translation cavity (722) that permits translation of lock member (730)within the confines of grounding member (720). Grounding member (720)further includes a distal stop portion (724) and a proximal annularflange (726). Distal stop portion (724) and proximal annular flange(726) together define a translation distance for lock member (730). Aswill be described in greater detail below, lock member (730) isgenerally free to translate within the longitudinal space definedbetween distal stop portion (724) and proximal annular flange (726).

Lock member (730) includes a translation member (732), a drive portion(738), and a button lock portion (740). Translation member (732) isgenerally configured to engage with grounding member (720). As will bedescribed in greater detail below, translation member (732) is slidablethrough a predetermined range of motion within translation cavity (722)of lock member (730) to define the translation limits of lock member(730). Translation member (732) includes a longitudinal portion (734)and an outwardly extending annular flange (736).

Longitudinal portion (734) extends distally from drive portion (738) fora length approximately corresponding to the length of button lockportion (740). As will be understood, the length of longitudinal portion(734) permits button lock portion (740) to translate into and out of agap between buttons (322, 324) and shaft assembly (142). Longitudinalportion (734) is configured with a diameter that is larger relative tobutton lock portion (740). Such a diameter permits spring (750) to beaccommodated within the inner diameter of longitudinal portion (734).

Flange (736) extends outwardly from longitudinal portion (734). Flange(736) is sized to fit within cavity (722) defined by grounding member(720). Flange (736) is additionally sized to engage with correspondingflange (726) of grounding member (720). This sizing maintainstranslation member (732) within cavity (722) of grounding member (720)and guides translation member (732) along a predefined translation path.

Drive portion (738) is configured for grasping and/or manipulation by anoperator. Drive portion (738) is disposed between longitudinal portion(734) and button lock portion (740). In the present example, driveportion (738) includes a slight proximal orientation to cover at leastsome of buttons (322, 324) when in a locked state. Although this featureis merely optional, in some instances it may be desirable to provide avisual indicator to an operator that lock assembly (710) is in a lockedstate.

Button lock portion (740) extends proximally from drive portion (738).Button lock portion (740) is configured to slide between the gap betweenbuttons (322, 324) and shaft assembly (140). As will be described ingreater detail below, when button lock portion (740) is disposed betweenbuttons (322, 324) and shaft assembly (140) lateral movement of buttons(322, 324) is physically arrested. Moreover, in some examples buttonlock portion (740) may comprise an electrically insulating material toprevent electrical conductivity between buttons (322, 324) and shaftassembly (140).

FIGS. 23 and 24 show an exemplary use of lock assembly (710). As can beseen in FIG. 23, lock assembly (710) is initially positioned in a lockedstate. In the locked state, lock member (730) is resiliently biasedproximally by spring (750) such that button lock portion (740) isdisposed between buttons (322, 324) and shaft assembly (140). Thispositioning locks buttons (322, 324) by two simultaneous mechanisms.First, button lock portion (740) electrically insulates outer sheath(142) of shaft assembly (140). As described above, buttons (322, 324)operate by closing an activation circuit when brought into contact withouter sheath (142) of shaft assembly (140). Thus, button lock portion(740) prevents closure of any activation circuits associated withbuttons (322, 324) by electrically insulating outer sheath (142)relative to buttons (322, 324). Second, button lock portion (740)provides a mechanical stop for buttons (322, 324) by filling the gapbetween buttons (322, 324) and shaft assembly (140).

To unlock the functionality of buttons (322, 324) described above, anoperator may exert a force on drive portion (738) to push lock member(730) distally, thereby overcoming the resilient bias of spring (750).Such a force will transition lock member (730) from the position shownin FIG. 23 to the position shown in FIG. 24. Once lock member (730) isin the position shown in FIG. 24, lock assembly (710) is in an unlockedstate.

When lock assembly (710) is transitioning to the unlocked state, lockmember (730) is generally permitted to translate through a predetermineddistance defined by grounding member (720). In particular, longitudinalportion (734) of translation member (732) translates within cavity (722)of grounding member (720) until flange (736) contacts distal stopportion (724) of grounding member (720). Further translation of lockmember (730) is prevented by contact between flange (736) and distalstop portion (724).

Once lock assembly (710) is transitioned to the unlocked state, buttons(322, 324) may be actuated as described above with respect to FIGS. 4-9.After an operator is finished actuating buttons (322, 324) as desired,the operator may release any force from drive portion (738). With suchforce released, lock member (730) will automatically transition back tothe locked position of FIG. 22 by the resilient bias of spring acting ondrive portion (738).

It should be understood that, in the present example, the operator mustmaintain a distally oriented force on lock member (730) (overcoming theproximal bias of spring (750)) to enable actuation of buttons (322,325). In some other versions, lock assembly (710) comprises detentfeatures, latching features, and/or other features that selectivelyretain lock member (730) in a distal position (FIG. 24). In suchversions, the operator may simply advance lock member (730) to thisdistal position and then release lock member (730) without having tocontinue pressing distally on lock member to enable actuation of buttons(322, 325). If desired, when the operator is finished actuation buttons(322, 325), the operator may release lock member (730) from the holdingfeature(s), which will allow spring (750) to drive lock member (730)back to the proximal position (FIG. 23). Various suitable features thatmay be used to selectively retain a longitudinal position of lock member(730) will be apparent to those of ordinary skill in the art in view ofthe teachings herein.

V. Exemplary Combinations

The following examples relate to various non-exhaustive ways in whichthe teachings herein may be combined or applied. It should be understoodthat the following examples are not intended to restrict the coverage ofany claims that may be presented at any time in this application or insubsequent filings of this application. No disclaimer is intended. Thefollowing examples are being provided for nothing more than merelyillustrative purposes. It is contemplated that the various teachingsherein may be arranged and applied in numerous other ways. It is alsocontemplated that some variations may omit certain features referred toin the below examples. Therefore, none of the aspects or featuresreferred to below should be deemed critical unless otherwise explicitlyindicated as such at a later date by the inventors or by a successor ininterest to the inventors. If any claims are presented in thisapplication or in subsequent filings related to this application thatinclude additional features beyond those referred to below, thoseadditional features shall not be presumed to have been added for anyreason relating to patentability.

Example 1

An ultrasonic instrument comprising: (a) a body, wherein the bodydefines a longitudinal axis, wherein the body is configured to receivean ultrasonic transducer; (b) an actuation assembly, wherein theactuation assembly comprises: (i) at least one annular activationmember, wherein the at least one annular activation member extendsangularly about the body along a 360 degree angular range, wherein theat least one annular activation member is configured to move laterallyrelative to the longitudinal axis of the body, and (ii) at least oneactivation circuit corresponding to the at least one annular activationmember; (c) a shaft assembly, wherein the shaft assembly comprises anacoustic waveguide; and (d) an ultrasonic blade, wherein the ultrasonicblade is in acoustic communication with the acoustic waveguide, whereinthe at least one activation circuit is configured to activate theultrasonic blade in response to lateral movement of the activationmember relative to the longitudinal axis of the body.

Example 2

The ultrasonic instrument of Example 1, wherein the at least one annularactivation member comprises a first annular activation member and asecond annular activation member, wherein the at least one activationcircuit comprises a first activation circuit and a second activationcircuit, wherein the first annular activation member corresponds to thefirst activation circuit and the second annular activation membercorresponds to the second activation circuit.

Example 3

The ultrasonic instrument of Example 2, wherein the first activationcircuit is configured to transition from an open state to a closed statein response to lateral movement of the first annular activation member,wherein the second activation circuit is configured to transition froman open state to a closed state in response to lateral movement of thesecond annular activation member.

Example 4

The ultrasonic instrument of any one or more of Examples 2 through 3,wherein the first activation circuit is configured to activate theultrasonic blade at a first energy level in response to lateral movementof the first activation member, wherein the second activation circuit isconfigured to activate the ultrasonic blade at a second energy level inresponse to lateral movement of the second activation member.

Example 5

The ultrasonic instrument of any one or more of Examples 1 through 5,wherein the at least one annular activation member comprises a circularring extending about the body.

Example 6

The ultrasonic instrument of Example 5, wherein the circular ringcomprises a conical portion.

Example 7

The ultrasonic instrument of Example 6, further comprising at least oneactuation member, wherein the at least one actuation member isconfigured to bear against the conical portion of the circular ring toresiliently bias the at least one annular activation member toward aposition that is coaxially aligned with the body.

Example 8

The ultrasonic instrument of any one or more of Examples 1 through 7,wherein the at least one activation circuit comprises a first conductorand a second conductor, wherein the at least one annular activationmember is configured to place the first conductor into contact with thesecond conductor.

Example 9

The ultrasonic instrument of Example 8, wherein the at least oneactivation circuit is configured to transition from the open circuitcondition to the closed circuit condition in response to contact betweenthe first conductor and the second conductor.

Example 10

The ultrasonic instrument of any one or more of Examples 1 through 9,further comprising a lock feature, wherein the lock feature isconfigured to prevent the at least one activation circuit fromactivating the ultrasonic blade.

Example 11

The ultrasonic instrument of Example 10, wherein the lock feature isconfigured to selectively electrically insulate the at least one annularactivation member relative to the shaft assembly.

Example 12

The ultrasonic instrument of any one or more of Examples 10 through 11,wherein the lock feature is configured to selectively impede lateralmovement of the at least one annular activation member relative to thelongitudinal axis of the body.

Example 13

The ultrasonic instrument of any one or more of Examples 1 through 12,wherein the actuation assembly further comprises a cam feature, whereinthe cam feature is configured to translate proximally in response tolateral movement of the at least one annular activation member relativeto the longitudinal axis of the body.

Example 14

The ultrasonic instrument of Example 13, wherein the actuation assemblyfurther comprises a contact switch, wherein the contact switch is incommunication with the at least one activation circuit, wherein the atleast one annular activation member is configured to actuate the contactswitch directly or via the cam feature.

Example 15

The ultrasonic instrument of Example 14, wherein the cam feature isconfigured to engage the contact switch in response to lateral movementof the at least one annular activation member relative to thelongitudinal axis of the body, wherein the contact switch is configuredto transition the at least one activation circuit to a closed circuitcondition when engaged with the cam feature.

Example 16

The ultrasonic instrument of Example 15, wherein the cam feature isresiliently biased to urge the at least one annular activation memberinto coaxial alignment with the longitudinal axis of the body, whereinthe at least one annular activation member is operable to drive the camfeature proximally into engagement with the contact switch in responseto lateral movement of the at least one annular activation memberrelative to the longitudinal axis of the body.

Example 17

An ultrasonic instrument comprising: (a) a body, wherein the bodydefines a longitudinal axis, wherein the body is configured to receivean ultrasonic transducer; (b) an actuation assembly, wherein theactuation assembly comprises: (i) at least one activation ring disposedcoaxially with the longitudinal axis of the body, and (ii) at least oneactivation circuit, wherein the at least one activation circuit isassociated with the at least one activation ring, wherein the at leastone activation circuit is responsive to transverse movement of the atleast one activation ring relative to the longitudinal axis of the bodyto transition between an open circuit condition and a closed circuitcondition; (c) a shaft assembly, wherein the shaft assembly comprises anacoustic waveguide; and (d) an ultrasonic blade, wherein the ultrasonicblade is in acoustic communication with the acoustic waveguide, whereinthe at least one activation circuit is operable to trigger activation ofthe acoustic waveguide.

Example 18

The ultrasonic instrument of Example 17, wherein the actuation assemblyfurther comprises a centering assembly, wherein the centering assemblyis configured to resiliently bias the activation ring toward a positionof coaxial alignment with the longitudinal axis of the body.

Example 19

The ultrasonic instrument of any one or more of Examples 17 through 18,wherein the at least one activation ring includes a conductor, whereinthe at least one circuit is in electrical communication with theconductor and at least a portion of the shaft assembly, wherein the atleast one activation circuit is configured to transition to the closedcircuit condition in response to movement of the activation ring intocontact with at least a portion of the shaft assembly.

Example 20

An ultrasonic instrument comprising: (a) a body, wherein the bodydefines a longitudinal axis, wherein the body is configured to receivean ultrasonic transducer; (b) an actuation assembly, wherein theactuation assembly comprises: (i) a annular activation member assembly,wherein the annular activation member assembly comprises a first annularactivation member and a second annular activation member, wherein thefirst and second annular activation members are disposed around thelongitudinal axis of the body, and (ii) an activation circuit assembly,wherein the activation circuit assembly includes a first activationcircuit and a second activation circuit, wherein the first activationcircuit is associated with the first annular activation member, whereinthe second activation circuit is associated with the second annularactivation member, wherein the activation circuit assembly is configuredto transition to an active state in response to lateral translation ofthe first annular activation member or the second annular activationmember relative to the longitudinal axis of the body; (c) a shaftassembly, wherein the shaft assembly comprises an acoustic waveguide;and (d) an ultrasonic blade, wherein the ultrasonic blade is in acousticcommunication with the acoustic waveguide, wherein the activationcircuit assembly is operable to trigger activation of the acousticwaveguide.

VI. Miscellaneous

It should be understood that any of the versions of instrumentsdescribed herein may include various other features in addition to or inlieu of those described above. By way of example only, any of theinstruments described herein may also include one or more of the variousfeatures disclosed in any of the various references that areincorporated by reference herein. It should also be understood that theteachings herein may be readily applied to any of the instrumentsdescribed in any of the other references cited herein, such that theteachings herein may be readily combined with the teachings of any ofthe references cited herein in numerous ways. Other types of instrumentsinto which the teachings herein may be incorporated will be apparent tothose of ordinary skill in the art.

It should also be understood that any ranges of values referred toherein should be read to include the upper and lower boundaries of suchranges. For instance, a range expressed as ranging “betweenapproximately 1.0 inches and approximately 1.5 inches” should be read toinclude approximately 1.0 inches and approximately 1.5 inches, inaddition to including the values between those upper and lowerboundaries.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Versions of the devices described above may have application inconventional medical treatments and procedures conducted by a medicalprofessional, as well as application in robotic-assisted medicaltreatments and procedures. By way of example only, various teachingsherein may be readily incorporated into a robotic surgical system suchas the DAVINCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif.Similarly, those of ordinary skill in the art will recognize thatvarious teachings herein may be readily combined with various teachingsof U.S. Pat. No. 6,783,524, entitled “Robotic Surgical Tool withUltrasound Cauterizing and Cutting Instrument,” published Aug. 31, 2004,the disclosure of which is incorporated by reference herein.

Versions described above may be designed to be disposed of after asingle use, or they can be designed to be used multiple times. Versionsmay, in either or both cases, be reconditioned for reuse after at leastone use. Reconditioning may include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, someversions of the device may be disassembled, and any number of theparticular pieces or parts of the device may be selectively replaced orremoved in any combination. Upon cleaning and/or replacement ofparticular parts, some versions of the device may be reassembled forsubsequent use either at a reconditioning facility, or by an operatorimmediately prior to a procedure. Those skilled in the art willappreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, versions described herein may be sterilizedbefore and/or after a procedure. In one sterilization technique, thedevice is placed in a closed and sealed container, such as a plastic orTYVEK bag. The container and device may then be placed in a field ofradiation that can penetrate the container, such as gamma radiation,x-rays, or high-energy electrons. The radiation may kill bacteria on thedevice and in the container. The sterilized device may then be stored inthe sterile container for later use. A device may also be sterilizedusing any other technique known in the art, including but not limited tobeta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

I claim:
 1. An ultrasonic surgical instrument, comprising: (a) a body,wherein the body defines a longitudinal axis, wherein the body isconfigured to receive an ultrasonic transducer; (b) a shaft assembly,wherein the shaft assembly comprises an acoustic waveguide; (c) anultrasonic blade, wherein the ultrasonic blade is in acousticcommunication with the acoustic waveguide; and (d) an actuationassembly, wherein the actuation assembly comprises: (i) a firstactivation circuit, wherein the first activation circuit is configuredtransition between a deactivated state and a first activated state,wherein the first activation circuit is configured to activate theultrasonic blade at a first energy level in the first activated state;(ii) a first annular activator corresponding to the first activationcircuit, wherein the first annular activator extends angularly about thebody along a 360 degree angular range in a first plane, wherein thefirst annular activator is configured to move laterally relative to thelongitudinal axis of the body in any radial direction from thelongitudinal axis in the first plane to transition the first activationcircuit from the deactivated state to the first activated state, and(iii) a camming assembly configured to resiliently bias the firstannular activator in any radial direction from the longitudinal axis inthe first plane toward a position associated with the first activationcircuit being in the deactivated state.
 2. The ultrasonic surgicalinstrument of claim 1, wherein the first annular activator is configuredto be coaxially aligned with the longitudinal axis of the body when thefirst activation circuit is in the deactivated state.
 3. The ultrasonicsurgical instrument of claim 1, wherein the actuation assembly furthercomprises a second activation circuit configured to transition between adeactivated state and a second activated state, wherein the secondactivation circuit is configured to activate the ultrasonic blade at asecond energy level in the second activated state.
 4. The ultrasonicsurgical instrument of claim 3, wherein the actuation assembly furthercomprises a second annular activator corresponding to the secondactivation circuit.
 5. The ultrasonic surgical instrument of claim 4,wherein the second annular activator extends angularly about the bodyalong a second 360 degree angular range in a second plane, wherein thesecond annular activator is longitudinally offset from the first annularactivator.
 6. The ultrasonic surgical instrument of claim 5, wherein thesecond annular activator is configured to move laterally relative to thelongitudinal axis of the body in any radial direction from thelongitudinal axis in the second plane to transition the least one secondactivation circuit from the deactivated state to the second activatedstate.
 7. The ultrasonic surgical instrument of claim 6, wherein thecamming assembly is configured to resiliently bias the second annularactivator in any radial direction from the longitudinal axis in thesecond plane toward a position associated with the second activationcircuit in the deactivated state.
 8. The ultrasonic surgical instrumentof claim 7, wherein the second annular activator is configured to becoaxially aligned with the longitudinal axis of the body when the secondactivation circuit is in the deactivated state.
 9. The ultrasonicsurgical instrument of claim 1, wherein the camming assembly comprisesan annular array of translating bodies disposed around the waveguide.10. The ultrasonic surgical instrument of claim 1, where the cammingassembly comprises a single translating body disposed around thewaveguide.
 11. The ultrasonic surgical instrument of claim 1, whereinthe first activation circuit comprises a plurality of conductivecontacts disposed within an interior of the first annular activator. 12.The ultrasonic surgical instrument of claim 1, wherein the firstactivation circuit comprises a conductive coating disposed within aninterior surface of the first annular activator.
 13. The ultrasonicsurgical instrument of claim 1, wherein the activation circuit comprisesan activation button disposed within the body, wherein the cammingassembly is configured to contact the activation button in response tothe first annular activator moving laterally relative to thelongitudinal axis of the body in any radial direction from thelongitudinal axis in the first plane.
 14. The ultrasonic surgicalinstrument of claim 1, further comprising a stop configured toselectively inhibit the first activated circuit from transitioning tothe first activated state.
 15. An ultrasonic surgical instrument,comprising: (a) a body, wherein the body defines a longitudinal axis,wherein the body is configured to receive an ultrasonic transducer; (b)a shaft assembly, wherein the shaft assembly comprises an acousticwaveguide; (c) an ultrasonic blade, wherein the ultrasonic blade is inacoustic communication with the acoustic waveguide; and (d) an actuationassembly, wherein the actuation assembly comprises: (i) a firstactivation circuit, wherein the first activation circuit is configuredtransition between a deactivated state and a first activated state,wherein the first activation circuit is configured to activate theultrasonic blade at a first energy level in the first activated state;(ii) a first annular activator corresponding to the first activationcircuit, wherein the first annular activator extends angularly about thebody along a 360 degree angular range in a first plane, wherein thefirst annular activator is configured to move laterally within the firstplane relative to the longitudinal axis of the body in a first radialdirection, a second radial direction, and a third radial direction totransition the first activation circuit from the deactivated state tothe first activated state, and (iii) a camming assembly configured toresiliently bias the first annular activator in the first radialdirection, the second radial direction, and the third radial directiontoward a position associated with the first activation circuit being inthe deactivated state.
 16. The ultrasonic surgical instrument of claim15, further comprising a lock assembly configured to selectively preventthe first annular activator from moving in the first radial direction,the second radial direction, and the third radial direction.
 17. Theultrasonic surgical instrument of claim 15, further comprising a lockassembly configured to prevent the first activation circuit fromtransitioning into the activated state.
 18. The ultrasonic surgicalinstrument of claim 15, wherein the camming assembly is annularlydisposed around the waveguide at first location aligned with the firstradial direction, a second location aligned with the second radialdirection, and a third location aligned with the third radial direction.19. A method of using an ultrasonic surgical instrument, comprising: (a)grasping a body housing a waveguide, wherein the waveguide is inultrasonic communication with an ultrasonic blade, wherein the bodydefines a longitudinal axis; (b) moving a first annular activator, as arigid unit in its entirety, in a first radial direction relative to thelongitudinal axis to activate a first activation circuit to therebyactivate the ultrasonic blade at a first energy level, wherein the firstradial direction is within a first plane; (c) moving the first annularactivator, in its entirety, in a second radial direction relative to thelongitudinal axis to activate the first activation circuit to therebyactivate the ultrasonic blade at the first energy level, wherein thesecond radial direction is within the first plane, wherein the secondradial direction is different than the first radial direction; and (d)moving the first annular activator in a third radial direction relativeto the longitudinal axis to activate the first activation circuit tothereby activate the ultrasonic blade at the first energy level, whereinthe third radial direction is within the first plane, wherein the thirdradial direction is different than the second radial direction and thefirst radial direction.
 20. The method of claim 19, further comprisingreleasing the first annular activator after moving the first annularactivator in the first radial direction to thereby allow a cammingassembly to actuate the first annular activator in a direction oppositethe first radial direction.